Nestable and stackable dunnage

ABSTRACT

Dunnage for storing and handling parts, such as automotive steering wheels, comprises identical vacuum-formed dunnage sections having tapering walls enabling the sections to be nested in each other. Sections may also be stacked upon each other and are provided with parts receiving pockets whereby when the sections are stacked to form a closed container, the pocket in the stacked sections cooperatively hold the parts separated from each other, thereby avoiding damage to the parts. Two or more of the dunnage containers may be stacked on each other and projections and cavities on the stacked containers interfit to prevent lateral movement and collapse of the stack.

BACKGROUND OF THE INVENTION

1. Field of the Invention

In the manufacture of automotive vehicles, and possibly in otherindustries as well, parts are shipped to the vehicle manufacturers whoinsert them into the vehicles as they pass down an assembly line. Theparts are shipped from the parts supplier to the vehicle assembly plantin dunnage which is filled by the parts supplier. The dunnage isintended to protect the parts during shipment and storage prior toinstallation in the vehicles. As the dunnage is emptied, it must be setaside and this causes disposal problems resulting in scraping thedunnage because of the space required for storage or shipment back tothe supplier. Similarly, considerable space is required for storage ofthe dunnage prior to use at the parts supplier or subsequent to use atthe assembly plant.

Similarly, when parts are delivered to the vehicle assembly plant, theymust be stored prior to use and this imposes further requirements on thesupplier to either find storage space for the dunnage containing theparts, or time the delivery accurately in accordance with themanufacturer's needs.

Accordingly, the need has arisen for a more economical handling of partscontained in dunnage or handling of the dunnage itself both during useand prior to or after use, so that a minimum of space is required at theparts supplier and at the vehicle manufacturer.

In addition to the foregoing, there has been a need for a moreeconomical form of dunnage, which if to be discarded after use does notresult in substantial financial loss. Similarly, after use of thedunnage, it would be desirable to be able to return the dunnage to theparts supplier for re-use or disposal as desired. This would appear onlyto be feasible if after use the dunnage can be very easily stored in acompact manner thereby resulting in substantial space-saving until itcan be disposed of or when disposed of, may even be shipped back to theparts supplier for re-use.

These requirements for handling the dunnage and storage of the parts haspresented a long-term challenge for industry which are at least in partmet in the following disclosure.

2. Background Art

The following U.S. patents show the state of the art relating todunnage-like products:

-   -   U.S. Pat. No. 3,376,046    -   U.S. Pat. No. 4,557,382    -   U.S. Pat. No. 4,643,306    -   U.S. Pat. No. 4,779,732    -   Re. 33,361    -   U.S. Pat. No. 5,046,615    -   U.S. Pat. No. 5,324,105    -   U.S. Pat. No. 5,409,110    -   U.S. Pat. No. 5,887,718

SUMMARY OF THE INVENTION

As herein disclosed, the dunnage is made up of identical vacuum-formedplastic sections that may be nested in one another when not in use,thereby occupying a minimum of space, and yet may be inverted andstacked on one another to form a closed container for receiving andholding parts to be stored and transported. The design of the plasticsections is such that the closed containers may themselves be stacked,such as three containers high, thereby facilitating the storage of partswaiting to be removed and put to use. The plastic sections haveprojections and recesses which interfit when the closed containers arestacked, thereby preventing the stacked containers from lateraldisplacement and collapse of the closed container stack.

The individual plastic sections may have pockets formed therein forreceiving parts to be handled, and when two plastic sections are instacked alignment they cooperatively hold the parts for storage andshipment. The plastic sections may have projections that interfit inrecesses or cavities in opposed sections to keep the stacked sections inproper alignment so that the sections will cooperatively hold the partsagainst any applicable movement relative to the dunnage. The projectionsor pockets may also have surfaces which are treated to preventscratching or damage to the surfaces of the parts stored in the dunnage.Such treatment may comprise adhering foam strips for othernon-scratching material to surfaces of the wall portions or pockets.

Thus, my design of the identical nestable and stackable dunnage enablesthe dunnage sections to:

-   -   (1) be nested one within another so that a substantial number        may be stored in a small space;    -   (2) dunnage sections may be inverted and stacked on one another        to form a closed container;    -   (3) the closed containers with products stored therein may be        stacked on one another to minimize the space required for        storage of products; and

(4) eliminates the need for an external container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the outside of one of the dunnagesections;

FIG. 2 is a perspective view of the inside of the dunnage section shownin FIG. 1;

FIG. 3 is a perspective view of two of the dunnage sections of FIGS. 1and 2 wherein one of the sections is inverted and stacked on the otherto form a closed parts-receiving container;

FIG. 4 is a perspective view of two of the dunnage containers of FIG. 2stacked on top of each other;

FIG. 5 is a perspective view showing two dunnage sections in registryand how an automotive steering wheel, for example, would be packagedbetween them;

FIG. 6 is a top view of the outside of a dunnage section;

FIG. 7 is a side elevation of a dunnage compartment formed by stackingtwo dunnage sections;

FIG. 8 is an end elevation of a dunnage compartment as shown in FIG. 7;

FIG. 9 is a side elevation as in FIG. 7 but stacked two containers high;

FIG. 10 is a cross-sectional view taken on the line 10-10 of FIG. 3;

FIG. 11 is a cross-sectional view taken on the line 11-11 of FIG. 3;

FIG. 12 is a cross-sectional view through the dunnage sections disposedin nested relation; and

FIG. 13 is a cross-sectional view taken along a vertical plane 13-13extending through the dunnage sections between the end walls.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

In FIG. 3 I have shown my dunnage in the form of a closed container orparts receiving enclosure 20 a made up of two identical dunnage sections22 and 24 arranged in stacked relationship. In FIG. 4 I have shown twoof the closed containers 20 b and 20 c stacked on one another. In use,the containers may be stacked three or more high as requested by theuser.

Preferably, the dunnage sections are vacuumed-formed of plastic, such ashigh weight molecular polyethylene. As shown in FIG. 2, each section hassubstantially identical opposed inwardly tapering side walls 28 and 30,opposed substantially identical inwardly tapering end walls 32 and 34,and a bridging wall 36 extending between the inwardly tapering ends ofthe side and end walls. An integral peripheral flange 38 extends aroundthe outer ends of the side and end walls.

Each side wall is shaped to provide a succession of outwardly projectingportions in the form of nine identical ribs, with the ribs on one sidewall being directly opposite the ribs on the opposite wall. Thus, theribs on side wall 28 are identified by reference numerals 40, 42, 44,46, 48, 50, 52, 54 and 56, and the ribs on side wall 30 being directlyopposite are identified by reference numerals 58, 60, 62, 64, 66, 68,70, 72 and 74. The inside of the ribs form pockets 76 as shown in FIGS.2 and 5 for receiving the products to be handled by the dunnage, such asautomotive steering wheels 78.

To protect the steering wheels from being scratched by the dunnage, athin strip of foam rubber or the like 80 may be adhered to the inside ofeach pocket, as shown in FIG. 5, which is in contact with the dunnage.From FIG. 5 it may be noted that the dunnage section 20 c substantiallyencloses the lower half of the steering wheel. Upon inverting anothersection of the dunnage such as section 20 b, it may be placed over theupper half of the steering wheel and when moved downwardly so that theflanges 38 a and 38 b of the two sections are brought into flushengagement, the steering wheel is supported in spaced relation at thetop and bottom out of engagement with other steering wheels in thedunnage.

To further prevent movement of the steering wheels, the bridging wall 36may be provided with a series of inward projections best shown in FIGS.1, 4, 6 and 13, at 80, 82, 84, 86, 88, 90, 92, 94 and 96. The exposedsurface of each such projection, which might come into contact with theparts being stored, is also covered with a thin layer of foam rubbersuch as at 98 (see FIG. 10) to prevent scratching of the steeringwheels.

Relative lateral movement between the dunnage sections when in thestacked condition shown in FIG. 3 is prevented by interfittingprojections 102 a and 102 b fitting into cavities 100 a and 100 b onopposite edges of opposed dunnage sections on the flanges 38, as shownin FIGS. 5, 6, 7 and 9. The cavities and projections are arranged in theflanges in opposition as best shown in FIG. 6. When the dunnage sectionsare stacked with the bridging walls in flush opposition as shown inFIGS. 4 and 9, relative lateral movement is prevented by a series ofprojections 104 a of the bridging wall of one dunnage section receivedin cavities 104 b of the opposite dunnage section as shown in FIGS. 2,3, 6 and 10 arranged in rows on opposite sides of the projections 80-94.The interfitting of projections on one dunnage section in the cavitiesor recesses in an opposed dunnage section serves to prevent bothlongitudinal and lateral relative movement between opposed dunnagesections, and enables stability in the closed container shown in FIG. 3and in the stacked arrangement of FIG. 4.

The dunnage sections can be nested as shown in FIG. 12 for storagepurposes. In such nested relation several dunnage sections may be storedin a relatively small space.

When desired for use with parts to be handled, the dunnage sections canbe removed from the nested relation and one section filled with theparts, as in FIG. 5, and once filled, a second dunnage section may beinverted and placed on top of the previously filled section with theparts interfitting with the pockets 76 as the dunnage container isclosed by the dunnage sections as in FIGS. 3 and 5.

As mentioned previously, the closed dunnage containers may be stackedone atop another as in FIG. 4 for storage or transport.

While I have shown the dunnage designed for reception and handling ofautomotive steering wheels, the dunnage may be designed for a variety ofparts, particularly parts whose shape lends them to be stored byinterfitting with identical dunnage sections.

FIGS. 5 and 7 illustrate how projections 102 a and 102 b along oppositeedges of a dunnage section interfit with cavities 100 a in oppositeedges of another identical dunnage section.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. Nestable and stackable dunnage for receiving and holding products fortransport and storage comprising: a plurality of identical dunnagesections having opposed inwardly tapering side walls, opposed inwardlytapering end walls, and a bridging wall extending between the inwardlytapering ends of the side and end walls; said walls having opposedproduct receiving pockets; projections and cavities on said dunnagesections for engaging each other when one dunnage section is invertedand stacked on another, to hold the dunnage and in turn said pockets inregistered alignment; and when the dunnage sections are in saidalignment, said pockets cooperate at spaced apart locations to holdproducts in said pockets out of contact with one another.
 2. Theinvention defined by claim 1 wherein upon removal of products from thedunnage sections, one section may be inverted and placed within anothersection in nested relation.
 3. The invention defined by claim 1 whereinthere are projections and cavities on the bridging wall for holdingdunnage sections in alignment when the sections are stacked with thebridging walls in immediate confronting relation.
 4. The inventiondefined by claim 1 wherein there is a peripheral flange extending aroundthe dunnage section at the wider end of said walls and there arecavities and projections in said flange at opposite sides of the dunnagesection for cooperation with corresponding opposed flanges on anotherdunnage section when the sections are in stacked relation.
 5. Nestableand stackable dunnage for receiving and holding parts for transportand/or storage comprising: a plurality of identical dunnage sectionshaving opposed inwardly tapering side walls, opposed inwardly taperingend walls, and a bridging wall extending between the inwardly taperingends of the side and end walls; said walls having opposed inwardlyopening parts receiving pockets whereby, when one dunnage section isinverted and stacked on another dunnage section, product receivingpockets may embrace upper and lower portions of parts to be handled; andprojections and cavities on said dunnage sections for engaging eachother when the sections are in the aforesaid stacked relation to holdthe dunnage sections against relative movement.
 6. Nestable andstackable dunnage for receiving and holding parts for transport andstorage comprising: a plurality of identical dunnage sections havingopposed inwardly tapering side walls, opposed inwardly tapering endwalls, and a bridging wall extending between the inwardly tapering endsof the side and end walls; said side walls having opposed inwardlyopening parts receiving pockets, whereby when one dunnage section isinverted and stacked on another dunnage section forming a partsreceiving enclosure, the parts receiving pockets within the enclosureembrace spaced apart portions of the parts to be handled; said bridgingwalls having projections and cavities for engagement with correspondingcavities and projections when one parts enclosure is stacked on anotherparts enclosure with the bridging walls in flush engagement; wherebysaid projections and cavities hold the dunnage sections against lateralmovement; and said dunnage sections being nestable, one within another,when one dunnage section is inverted and stacked within another dunnagesection.
 7. Nestable and stackable dunnage for receiving and holdingparts for transport and storage comprising: a plurality of identicaldunnage sections having opposed inwardly tapering side walls, opposedinwardly tapering end walls, and a bridging wall extending between theinwardly tapering ends of the side and end walls; said side walls havingopposed inwardly opening parts receiving pockets, whereby when onedunnage section is inverted and stacked on another dunnage sectionforming a parts receiving enclosure, the parts receiving pockets withinthe enclosure embrace spaced apart portions of the parts to be handled;and said dunnage sections being nestable one within another when onedunnage section is inverted and stacked within another dunnage section.